Method of producing an ornamental concrete surface

ABSTRACT

A METOD OF PRODUCNG AN ORNAMENTAL CONCRETE SURFACE WHEREIN A COATING OF AN AIR SETTABLE, WATER PLASTICIZABLE ADHESIVE IS APPLIED TO THE INNER SURFACE OF A FORM FOR CONTAINING CONCRETE. PARTICULATE MATERIAL IS PLACED ON THE COATING AND PARTIALLY EMBEDDED IN THE SUBSTANCE. THE SUBSTANCE THEN IS ALLOWED TO SET SO THAT THE PARTICLES BECOME BONDED THERTO. THE FORM IS THEN POSITIONED FOR CONTANING CONCRETE AND CONCRETE IS INTRODUCED AGAINST THE INNER SURFACE THEREOF. THE CONCRETE IS THEN ALLOWED TO SET SO THAT THE PARTICLES BECOME BONDED TO THE CONCRETE AND THE SUBSTANCE IS AT LEAST PARTIALLY PLASTICIZED BY THE WATER IN THE CONCRETE. THE FORM IS THEN REMOVED FROM THE CONCRETE SURFACE FORMED BY THE INNER SURFACE THEREOF SO THAT THE PARTICLES ARE SEPARATED FROM THE SUBSTANCE AND REMAIN BONDED TO THE CONCRETE, TO THEREBY ORNAMENT THE CONCRETE SURFACE.

' T. R. DILLON June 5, 1973 METHOD OF PRODUCING AN ORNAMENTAL CONCRETE SURFACE 2 Sheets-Sheet 1 Original Filed Nov. 28, 1969 m gf" 3.

INVENTOR 704/) 2. 5/4 4 0M ATTORNEYS T. R. DILLON June 5, 1973 METHOD OF PRODUCING AN ORNAMENT/AL CONCRETE SURFACE 2 Sheets-Sheet 2 Original Filed Nov. 28, 1969 INVENTOR 70m 2. Ba: 01v

United States Patent 3,737,511 METHOD OF PRODUCING AN ORNAMENTAL CONCRETE SURFACE Tony R. Dillon, RR. 1, Urbana, Ill. 61801 Continuation of abandoned application Ser. No. 880,838, Nov. 28, 1969. This application Jan. 11, 1972, Ser.

Int. Cl. B28b 1/16 US. Cl. 264-256 6 Claims ABSTRACT OF THE DISCLOSURE A method of producing an ornamental concrete surface wherein a coating of an air settable, water plasticizable adhesive is applied to the inner surface of a form for containing concrete. Particulate material is placed on the coating and partially embedded in the substance. The substance then is allowed to set so that the particles become bonded thereto. The form is then positioned for containing concrete and concrete is introduced against the inner surface thereof. The concrete is then allowed to set so that the particles become bonded to the concrete and the substance is at least partially plasticized by the water in the concrete. The form is then removed from the concrete surface formed by the inner surface thereof so that the particles are separated from the substance and remain bonded to the concrete, to thereby ornament the concrete surface.

This is a continuation application of application Ser. No. 880,838, filed Nov. 28, 1969.

BACKGROUND OF THE INVENTION Field of the invention This invention relates to a method of producing ornamental concrete surfaces, and specifically, to a method wherein particulate material is bonded to a concrete surface at the time the concrete comprising the surface sets.

BRIEF DESCRIPTION OF THE PRIOR ART Several methods are known for producing ornamental concrete surfaces in which a particulate ornamenting material is placed adjacent such a surface while the concrete is setting so that the material becomes bonded to the surface. Exemplary of such methods are those disclosed in Johnson Pat. 1,691,721 and Weiner et al., Pat. 3,390,496. r

The method taught in the Johnson patent includes applying a coating of an air settable, water plasticizable adhesive to a sheet of flexible material and thereafter placing the ornamenting material on such coating. The adhesive also contains a substance which inhibits the setting of concrete. After the adhesive has set, the flexible sheet material is secured to the inner surface of a form for containing concrete, as by nailing or the like. Concrete is then introduced against the form and allowed to set so that the ornamenting material becomes bonded to the concrete. Also as the concrete sets, the adhesive is plasticized by the water in the concrete and the portion of the concrete adjacent the ornamenting material is prevented from setting by the set-inhibiting substance. Thereafter, when the form is removed the ornamenting material remains bonded to the concrete and is separated from the adhesive. Due to the action of the set-inhibiting substance, the outer extremities of the ornamenting particles are substantially relieved from the adjacent concrete surface.

The method taught in the Weiner et al. patent is generally similar to that disclosed in the Johnson patent. However, in the Weiner et al. method the adhesive coating is applied directly to the inner surface of the form,

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thereby eliminating the use of an intermediate sheet of flexible material. The adhesive employed in the Weiner et al. process is water insoluble and includes a sublimating agent. The bond between the ornamenting material and adhesive is destroyed, after the concrete has set, by sublimation rather than plasticization of the adhesive. Moreover the adhesive coating used in the Weiner et al. method is relatively thick so that the ornamenting material may include particles of various sizes, resulting in wide variations in the relief of the outer particle extremities from the adjacent concrete surface.

The Johnson and Weiner et al. methods are basically operative for the purpose intended. However, these methods include technical and economic disadvantages which severely limit their use on a commercial scale. For example, the Johnson method requires the use of an intermediate sheet of flexible material which increases both the cost and complexity of the method. Also, the outer extremities of the ornamenting particles employed in both the Johnson and Weiner et al. methods are substantially relieved from the adjacent concrete surface. In particular, and as shown in FIG. 4 of the Johnson patent, and FIG. 2 of the Weiner et al. patent, for many of the particles the surface area contacted by the concrete is relatively small in comparison to the total surface area of the particles. The particles thus may tend to become dislodged from the concrete over a period of time due to the adverse effects of weather. This result obviously reduces the decorative effect of the ornamenting material.

Therefore, a need exists for a method of producing ornamental concrete surfaces, which method is relatively inexpensive and produces a durable surface.

SUMMARY OF THE INVENTION The method of the invention is adapted to obviate the problems associated with the above-described prior art methods of producing ornamental concrete surfaces. Basically described, the method of the invention consists of the steps of: applying a coating of an air settable, water plasticizable adhesive to the inner surface of a form for containing concrete; placing particulate material on the coating before the adhesive sets and embedding substantially all of the particles of said material in the adhesive such that no greater than one-half of the surface area of each embedded particle is contacted by the adhesive; allowing the adhesive to set so that the particles embedded therein become bonded thereto; removing any particles from the coating not embedded in the adhesive; positioning the form for containing concrete; introducing concrete against said inner surface to thereby embed the particles embedded in the adhesive in the concrete such that at least one-half of the surface area of each particle embedded in the adhesive is contacted by the concrete; allowing the concrete to set so that the particles embedded in the concrete become bonded thereto and the adhesive is at least partially plasticized by the water in the concrete; and removing the form from the concrete surface formed by said inner surface so that the particles embedded in the concrete are separated from the adhesive and remain bonded to the concrete, thereby ornamenting the concrete surface with the particles.

The particulate material preferably comprises particles of relatively uniform size each having a volume in the range of 3 -34; cubic inch.

Also, the adhesive preferably comprises a readily available, relatively inexpensive substance, such as a linoleum paste having low water resistance.

With the foregoing in mind, it is an object of the present invention to provide an improved method of producing an ornamental concrete surface.

It is also an object of the invention to provide a method of producing an ornamental concrete surface, which method is relatively inexpensive and produces a durable surface.

It is a further object of the invention to provide a method of producing an ornamental concrete surface in which an ornamenting particulate material is securely bonded to the surface during the setting of the concrete.

These and other objects of the invention will become apparent upon a consideration of the detailed description of a preferred embodiment thereof given in connection with the following drawings, wherein like reference numerals identify like elements throughout.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a form for containing concrete having a coating of adhesive applied to the inner surface thereof and a quantity of particulate material placed on such coating, all in accordance with the method of the invention;

FIG. 2 is a sectional view taken on line 22 of FIG. 1;

FIG. 3 is a sectional view taken on line 33 of FIG. 1;

FIG. 4 is a sectional view of the form shown in FIG. 1 and a portion of a concrete wall, showing the manner in which the form is employed for containing concrete in accordance with the method of the invention; and

FIG. 5 is a sectional view of a portion of a concrete wall, showing the ornamental concrete surface produced in accordance with the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT The method of the invention is described hereinbelow with reference to FIGS. 1-5. Initially a rigid form for containing concrete, such as form 10, is placed in a substantially horizontal position with the inner surface of the form facing upwardly. A coating 12 of an air settable, water plasticizable adhesive is then applied to such surface. An example of a suitable adhesive is a linoleum paste having low water resistance. The bonding agent in such paste generally comprises concentrates from the waste liquor obtained in a sulfite pulping process which contain complex lignin compounds. This adhesive is readily available at a relatively low cost.

The adhesive may be applied to the inner surface of the form in any suitable manner, as by spreading or spraying. One expeditious and economical manner of applying the adhesive is with a linoleum paste spreader. Such a spreader has a plurality of notches formed in the end thereof so that coating 12 comprises a plurality of rows 14, as shown in FIG. 2. Care must be exercised when applying the adhesive not to apply an excessive amount for a reason discussed in detail below.

Aftercoating 12 has been applied to the inner surface of form and before the adhesive has set, particulate material, such as rock particles 16, is placed on the coating. Substantially all of the particles are embedded in the adhesive such that no greater than one-half of the sufface area of each particle is contacted by the adhesive. It is for this reason that care must be exercised not to apply an excessive amount of adhesive to the inner surface of form 10. In order to obtain the desired density of embedded particles per unit area of the form inner surface, it is generally necessary to place more particles of the coating than are actually included in the final adhesive-particle composite. The adhesive is then allowed to set so that the particles embedded therein become bonded thereto, as shown in FIG. 3.

Form 10 is then moved to a generally vertical position and the outer surface of the form struck with a heavy tool, such as a hammer, to remove the particles from coating 10 which are not embedded in the adhesive.

Form 10 is then positioned for containing concrete, as shown in FIG. 4. Concrete 18 is thereafter introduced against the inner surface of the form in a continuous manner until the form is filled. This latter feature is important because any prolonged interruption in the introduction of concrete may result in the particles 16 adjacent the top of the concrete becoming separated from coating 12 due to the adhesive being plasticized by the water in the concrete.

As the concrete is introduced against the inner surface of the form, the particles embedded in the adhesive are embedded in the concrete such that at least one-half of the surface area of each particle is contacted by the concrete. This feature insures that the particles are securely bonded to the concrete, and is necessary to provide the desired durability of the ornamental surface produced by the method of the invention.

After the form has been filled, concrete 18 is allowed to set and harden. During the setting of the concrete, the water therein at least partially plasticizes the adhesive so that particles 16 are released by coating 12 and become bonded to the concrete. Generally, it has been found that the concrete should be allowed to set for at least 48 hours to insure that the particles are securely bonded to the concrete.

Thereafter form 10 is removed from the surface of the concrete formed by the inner surface thereof, at which time the particles are separated from the adhesive and remain bonded to the concrete, as shown in FIG. 5. Any small amounts of the adhesive adhering to the concreteparticle surface may be removed with water and a brush.

As also shown in FIG. 5, the outer extremities of the particles are not substantially relieved from the adjacent concrete surface. In fact, such relief is relatively minor and uniform across the surface. The decorative effect of the particles is not achieved by a substantial relief between the outer extremities thereof and the adjacent concrete surface, but rather by the appearance of the particles themselves.

The particles may comprise any number of materials which will bond securely to concrete. Examples of such materials are rock chips, wood chips, metallic chips and regular and irregular configured particles of synthetic ma terials. Also if desired, the particles may be of different colors.

It has been found that particles of substantially uniform size each having a volume in the range of 612 /g cubic inch provide an attractive appearance for general purpose use, such as for the exterior surfaces of a home. However, larger or smaller particles may be employed to provide other desired decorative effects.

As is apparent, the method of the invention provides a relatively inexpensive method of producing durable ornamental concrete surfaces. Consequently, the method is ideally suited for use on a commercial scale.

While the foreging constitutes a detailed description of the method of the invention, it is recognized that various modifications thereof will occur to those skilled in the art. Therefore, the scope of the invention is to be limited solely by the scope of the appended claims.

I claim:

1. A method of producing an ornamental concrete surface, consisting of the steps of positioning a rigid form for containing concrete substantially horizontally with the inner surface of the form facing upwardly;

applying a coating of an air settable, water plasticizable adhesive containing a lignin compound on said inner surface;

placing particulate material consisting of substantially uniformly sized particles each having a volume of cubic inch or greater on said coating before the adhesive sets and embedding substantially all of said particles in the adhesive such that no greater than one-half of the surface area of each embedded particlen's contacted by the adhesive;

allowing the adhesive to set so that the particles embedded therein become bonded thereto;

removing any particles from said coating not embedded in the adhesive;

positioning the form so as to form a mold cavity for containing concrete;

introducing concrete against said inner surface to thereby embed the particles embedded in the adhesive in the concrete such that at least one-half of the surface area of each particle embedded in the adhesive is contacted by the concrete;

allowing the concrete to set so that the particles embedded in the concrete become bonded thereto and simultaneously plasticizing the adhesive with the water of said concrete; and

removing the form from the concrete surface formed by said inner surface so that the particles embedded in the concrete are separated from the adhesive and remain bonded to the concrete, thereby ornamenting the concrete surface with the particles.

2. A method as recited in claim 1, wherein the 'volume of each of said particles is in the range of cubic inch.

3. A method as recited in claim 1, wherein said coating is formed by spreading said adhesive on said inner surface.

4. A method as recited in claim 1, wherein the bonding agent of said adhesive comprises concentrates from the waste liquor produced in a sulfite pulping process.

5. A method as recited in claim 1, wherein the particles not embedded in the adhesive are removed from said coating by striking the outer surface of said form.

6. A method as recited in claim 1, wherein said concrete is introduced against said inner surface substantially continuously until said form is filled.

References Cited OTHER REFERENCES Websters Seventh New Collegiate Dictionary, C&C Merriam Co., Springfield, Mass. (1967) p. 796 relied on.

ROBERT F. WHITE, Primary Examiner W. E. HOAG, Assistant Examiner US. Cl. X.R. 117-100 A 

